Vacuum cleaner equipped with suction relief nozzle assembly

ABSTRACT

A vacuum cleaner includes a body having a canister assembly and a nozzle assembly. A suction generator and dirt collection vessel are carried on the body. Further the nozzle assembly includes a housing including an electronic/electrical component compartment a bottom plate and an agitator cavity. An agitator drive motor and a printed circuit board are held in the electronic/electrical component compartment. A rotary agitator is held in the agitator cavity. A suction relief inlet is provided in the housing above the bottom plate. A passageway is also provided for directing air from the suction relief inlet through the electronic/electrical component compartment to the agitator cavity adjacent the bottom plate.

This utility patent application claims the benefit of priority in U.S. Provisional Patent Application Ser. Nos. 61/900,073 filed on Nov. 5, 2013; 61/941,110 filed on Feb. 18, 2014; and 61/972,544 filed on Mar. 31, 2014, the entirety of all disclosures of which are incorporated herein by reference.

TECHNICAL FIELD

This document relates generally to the floor care equipment field and, more particularly, to a vacuum cleaner equipped with a suction relief nozzle assembly. That assembly maintains proper airflow through the suction inlet of the vacuum cleaner even when the bottom plate of the nozzle assembly becomes sealed around the agitator cavity inlet by an underlying carpet or other surface being cleaned.

BACKGROUND

Floor care cleaning equipment such as central vacuum cleaners, canister vacuum cleaners and upright vacuum cleaners have long been known in the art. Such vacuum cleaners incorporate a fan and motor assembly that generates negative air pressure to draw dirt and debris into the vacuum cleaner. Many incorporate a nozzle assembly equipped with a rotary agitator that beats dirt and debris from the nap of an underlying carpet or rug in order to provide additional cleaning action. Entrained dirt and debris are removed from the airstream and collected in a dirt collection vessel such as a dirt cup or filter bag constructed of porous filter material. Some vacuum cleaners rely strictly upon bags or filters to clean dirt and debris from the airstream while others also utilize cyclonic airflow principles.

At certain times during operation, the bottom plate of the nozzle assembly may have a tendency to seal against the surface being cleaned thereby restricting airflow through the vacuum cleaner. This compromises cleaning efficiency and generates excessive intra-nozzle suction making it very difficult to push and pull the vacuum cleaner nozzle back-and-forth across the surface being cleaned. This document relates to a vacuum cleaner equipped with a suction control valve to maintain proper airflow through the vacuum cleaner for maximum cleaning efficiency, while preventing the bottom plate from sealing against the surface being cleaned. In this way the new vacuum cleaner affords easy push/pull of the nozzle assembly. Advantageously, the airstream from the suction relief valve passes over one or more electronic/electrical components of this nozzle assembly so as to also provide cooling.

SUMMARY

In accordance with the purposes and benefits described herein, a vacuum cleaner is provided comprising a body including a canister assembly and a nozzle assembly. A suction generator and a dirt collection vessel are both carried on that body. Further the nozzle assembly includes (a) a housing including an electronic/electrical component compartment, a bottom plate and an agitator cavity; (b) a rotary agitator held in the agitator cavity; (c) at least one electronic/electrical component held in the electronic/electrical component compartment, (d) a suction relief inlet provided in the housing above the bottom plate and allowing air to be drawn into the electronic/electrical component compartment and (e) a passageway for directing air from the electronic/electrical component compartment to the agitator cavity adjacent the bottom plate.

In one possible embodiment, the vacuum cleaner further includes an airflow control valve for controlling the flow of air through the suction relief inlet. Together, the suction relief inlet and airflow valve comprise the suction control valve. In at least one embodiment, the suction relief inlet comprises a right side inlet on a right side of the housing and a left side inlet on a left side of the housing. More specifically, the airflow control valve comprises a first flexible and resilient flap internal to and covering the right side inlet and a second flexible and resilient flap internal to and covering the left side inlet. The two flaps are normally biased into a closed position but are displaced into an open position when the bottom plate seals against an underlying carpet or surface to be cleaned. This serves to relieve excessive intra-nozzle suction, allowing the nozzle assembly to be easily pushed and pulled back-and-forth across the carpet or surface being cleaned.

In one possible embodiment, the vacuum cleaner includes an agitator cavity shield between the housing and the agitator. The passageway is formed between the outer surface of this agitator cavity shield and an inner surface of the housing. The passageway directs air from the electronic/electrical component compartment, ideally to the outer perimeter of the agitator cavity at a level even with or optimally and minimally just above the bottom plate.

In the following description, there are described several preferred embodiments of the vacuum cleaner. As it should be realized, the vacuum cleaner is capable of other, different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the vacuum cleaner as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the vacuum cleaner and together with the description serve to explain certain principles thereof. In the drawings:

FIG. 1 is a perspective view of a canister vacuum cleaner equipped with a nozzle assembly incorporating a suction relief/airflow control valve system.

FIG. 2 is a top plan view of the nozzle assembly with the upper housing and agitator cavity shield removed illustrating the flow of air from the suction relief inlets over the circuit board and motor and then along the agitator drive belt pathway to the agitator cavity.

FIG. 3 is a schematical cross-sectional view illustrating an alternate air flow pathway to that shown in FIG. 2.

FIG. 4 is a perspective view of the bottom plate of the nozzle assembly with the upper housing removed and illustrating a second embodiment wherein the suction relief inlets receive and hold air flow control valves.

FIG. 5 a illustrates one of the air flow control valves in a closed position.

FIG. 5 b illustrates one of the air flow control valves in an open position.

FIG. 6 is a perspective view of an upright vacuum cleaner equipped with a nozzle assembly having a suction relief/airflow control valve system as described in this document.

Reference will now be made in detail to the present preferred embodiments of the vacuum cleaner, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION

Reference is now made to FIG. 1 illustrating a canister vacuum cleaner 10 that has a canister assembly 12 that houses a suction generator 15 (shown inside the broken away housing) and supports a dirt collection vessel 14. The vacuum cleaner 10 also includes a nozzle assembly 16 that is connected by means of a swivel 18 to a cleaning wand 20 connected to a control handle 22. A flexible hose 24 connects the control handle 22 to the canister assembly 12. In operation, the suction generator 15 draws dirt and debris into the nozzle assembly 16 and through the wand 20, control handle 22 and flexible hose 24 into the inlet 26 of the canister assembly 12. Dirt and debris are separated from the airstream and held in the dirt collection vessel 14 before the suction generator 15 exhausts the now clean air back into the environment.

As illustrated in FIGS. 1 and 2, the nozzle assembly 16 includes a housing comprising a base portion 28 and a housing cover 30. The base portion 28 holds various components of the nozzle assembly 16 including, for example, a printed circuit board 32, an agitator drive motor 34 and an agitator drive belt 36. An agitator cavity shield 38 is provided over the rotary agitator 35 between the housing base portion 28 and the housing cover 30 (see also FIG. 3).

As further illustrated in FIG. 3, the housing also includes a bottom plate 40 having an agitator cavity inlet 42 that leads to the rotary agitator 35 disposed in the agitator cavity 44 defined between the agitator cavity shield 38 and the bottom plate 40. In one possible embodiment, the agitator cavity shield 38 and the portion of the housing cover 30 overlying the shield are transparent so that the operator may view the rotary agitator 35.

As further illustrated in FIGS. 2 and 3, two suction relief inlets 46 are provided in the rear wall on the right and left sides of the housing base portion 28 above the bottom plate 40. During vacuum cleaner operation, the suction generator 15 draws some air through the two suction relief inlets 46. As illustrated by the action arrows A in FIG. 2, that air flows through the electronic/electrical component compartment 31 providing cooling to the electronic/electrical components held therein such as the printed circuit board 32 and agitator drive motor 34. That air is then (i) minimally drawn along the belt guard 33 that defines the agitator drive belt pathway (note action arrows B) and into the rear of the agitator cavity 44 where it is entrained with dirt and debris being beaten by the rotary agitator 35 from an underlying carpet being cleaned (FIGS. 2) and/or (ii) drawn predominantly through a cooling slot (or slots) 48 in the sealing wall of the housing cover 30 into passageway 62 formed between (a) the inner surface of the housing cover 30 and (b) the outer or upper surface of the agitator shield 38 (see FIG. 3), where it is delivered to the agitator cavity 44 at the front edge of the nozzle assembly 16 just above the bottom plate 40 for maximum cleaning (note action arrows C in FIG. 3) where it can sweep across the rotary agitator 35 and entrain dirt and debris as it is drawn toward the main suction tube 64. From this point, the dirt-laden air is drawn through the cleaning wand 20 and flexible hose 24 to the dirt collection vessel 14.

In an alternative embodiment illustrated in FIGS. 4, 5 a and 5 b, airflow control valves, generally designated by reference numeral 50, are provided in the suction relief inlets 46. As best illustrated in FIGS. 5 a and 5 b, each airflow control valve 50 comprises a flexible flap 52 sized and shaped to seat over the suction relief inlet 46 in the rear wall of the housing base portion 28 (inlets 46 may also be located in the rear wall of the housing cover 30). More specifically, each flexible flap 52 includes a slot 54 that is received over a cooperating lug 56 projecting from the housing base portion 28.

A latching element 58 snaps over the lug 56 and secures the flexible flap 52 in position. During normal vacuum cleaner operation (FIG. 5 a), the flexible flaps 52 are biased to remain seated against the housing base portion 28 at least partially closing the suction relief inlets 46 and thereby allowing the passage of only enough air to cool the electronic/electrical components. Thus, during normal vacuum cleaner operation, the suction generator 15 draws nearly all of the air running through the vacuum cleaner 10 through the agitator cavity inlet 42 into the agitator cavity 44, for effective cleaning.

Reference is now made to FIG. 5 b which illustrates the operation of the air flow control valves 50 when normal vacuum cleaner operation is not possible for some reason. For example, at certain times and under certain conditions, such as when vacuuming “super-soft” or “ultra-soft” carpet, the thick carpet pile may effectively seal off the agitator cavity inlet 42 in the bottom plate 40 thereby preventing the normal flow of air through the nozzle assembly 16. As the flow of air through the agitator cavity inlet 42 decreases, the suction generator 15 continues to draw a vacuum. As the negative pressure builds, the flexible flaps 52 are drawn away from the housing base portion 28 and the airflow control valves 50 open. A greater volume of air is then drawn through the suction relief inlets 46 into the electronic/electrical component compartment 31. That air is then drawn over the electronic/electrical components held in that compartment (note, for example, the agitator drive motor 34 and the PCB 32) so as to provide a greater degree of cooling and then predominantly through a cooling slot (slots) 48 in the sealing wall of the housing cover 30 into the passageway 62 formed between (a) the inner surface of the housing cover 30 and (b) the outer or upper surface of the agitator cavity shield 38 (see FIG. 3), where it is delivered to the agitator cavity 44 at the front edge of the nozzle assembly 16 just above the bottom plate 40 for maximum cleaning (note action arrows C in FIG. 3) where it can sweep across the rotary agitator 35 and entrain dirt and debris as it is drawn toward the main suction tube 64. Significantly, this relief air breaks the seal between the bottom plate 40 and the surface being cleaned thereby relieving excessive suction and allowing one to easily push and pull the nozzle assembly 16 across the floor. When the sealed condition of the agitator cavity inlet 42 is sufficiently relieved as when moving nozzle onto bare floor or lower knap carpet, the negative pressure within the nozzle assembly 16 drops below a predetermined value and the flexible flaps 52 again return to their home or static position, closing the suction relief inlets 46.

In summary, the vacuum cleaner 10 is equipped with suction relief inlets 46 that provide for airflow over the electronic/electrical components 32, 34 held in the electronic/electrical component compartment 31 so as to provide cooling for enhanced operation of those components over a long service life. In another embodiment, airflow control valves 50 provide numerous benefits and advantages. In the event the agitator cavity inlet 42 in the bottom plate 40 becomes partially or fully sealed, the flexible flaps 52 of the valves 50 open allowing the suction generator 15 to draw in air to facilitate easy push/pull and maintain optimum cleaning performance. This not only cools the electronic/electrical components 32, 34 but also provides an auxiliary flow of air to release any sealing that might otherwise occur between the bottom plate 40 of the nozzle assembly 16 and the carpet being cleaned. This makes it easier to push and pull the vacuum cleaner under subsequently any operating conditions.

Up to this point, this document has only described and illustrated a canister vacuum cleaner. Reference is now made to FIG. 6 illustrating an upright vacuum cleaner 100 including an upper body assembly 102, holding a suction generator and dirt collection vessel (not shown), that is pivotally connected to a nozzle assembly 104 equipped with suction relief inlets 46 (hidden from view at the rear of the nozzle assembly) corresponding to those described above with respect to the canister vacuum cleaner embodiment. Those inlets 46 may or may not include the airflow control valves 50.

The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the vacuum cleaner to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. For example, while a canister vacuum cleaner 10 and upright vacuum cleaner 100 have been illustrated and described, it should be appreciated that other, additional embodiments are contemplated and encompassed in the following claims. Such embodiments include a central vacuum cleaner system incorporating a nozzle assembly with the airflow control valves for suction relief purposes. Further, while the illustrated nozzle assembly 16 includes a rotary agitator 35 disposed in an agitator cavity 44, it should be appreciated that the nozzle assembly could include a simple suction cavity and no rotary agitator. Still further, while the illustrated airflow control valves 50 include resilient, flexible flaps 52 that respond to changes in suction pressure, it should be appreciated that the valves 50 may be spring-biased gate valves, plunger valves, shutter type valves or the like, wherein the spring element may be a compression, tension, torsion, leaf spring or other suitable design. Further, the valves may be electronic/electrical in nature, comprising electronic/electrical sensors and actuation mechanism. Finally, it should be appreciated that all such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. 

What is claimed:
 1. A vacuum cleaner, comprising: a body including a canister assembly and a nozzle assembly; a suction generator carried on said body; and a dirt collection vessel carried on said body; said nozzle assembly including; (a) a housing including an electronic/electrical component compartment, a bottom plate and a cavity; (b) at least one electronic/electrical component held in said electronic/electrical component compartment; (c) at least one suction relief inlet provided in said housing above said bottom plate allowing air to be drawn into said electronic/electrical component compartment; and (d) a passageway for directing air from said electronic/electrical component compartment to said agitator cavity adjacent said bottom plate.
 2. The vacuum cleaner of claim 1, further including at least one airflow control valve for controlling a flow of air through each said suction relief inlet.
 3. The vacuum cleaner of claim 2, wherein said passageway directs air from said electronic/electrical component compartment toward said agitator cavity.
 4. The vacuum cleaner of claim 3, further including a rotary agitator in said cavity, an agitator drive motor held in said electronic/electrical component compartment and an agitator drive belt extending between said rotary agitator and said agitator drive motor.
 5. The vacuum cleaner of claim 4, wherein said passageway extends along said agitator drive belt.
 6. The vacuum cleaner of claim 2, wherein said airflow control valve comprises a flexible and resilient flap covering said suction relief inlet wherein said flap is normally biased into a closed position but is displaced into an open position when said bottom plate seals against an underlying carpet.
 7. The vacuum cleaner of claim 6, further including an agitator cavity shield between said housing and said agitator, said passageway being formed between an outer surface of said agitator cavity shield and an inner surface of said housing.
 8. The vacuum cleaner of claim 7, wherein said agitator cavity shield is transparent and said housing includes a transparent cover over said agitator cavity shield.
 9. The vacuum cleaner of claim 1, wherein at least one said suction relief inlet is located in a rear wall of said housing and communicates directly with said electronic/electrical component compartment.
 10. The vacuum cleaner of claim 9, further including at least one airflow control valve for controlling a flow of air through each said suction relief inlet(s).
 11. The vacuum cleaner of claim 10, wherein said airflow control valve comprises a flexible and resilient flap covering said suction relief inlet wherein said flap is normally biased into a closed position but is displaced into an open position when said bottom plate seals against an underlying carpet.
 12. The vacuum cleaner of claim 11, further including an agitator cavity shield between said housing and said agitator, said passageway being formed between an outer surface of said agitator cavity shield and an inner surface of said housing.
 13. The vacuum cleaner of claim 12, wherein said agitator cavity shield is transparent and said housing includes a transparent cover over said agitator cavity shield.
 14. The vacuum cleaner of claim 1, wherein said at least one electronic/electrical component is selected from a group consisting of (a) an agitator drive motor, (b) a printed circuit board, and (c) an agitator drive motor and a printed circuit board and wherein said at least one electronic/electrical component is cooled by said air being dawn through said suction relief inlet, over said at least one electronic/electrical component and through said passageway to said agitator cavity.
 15. The vacuum cleaner of claim 14, wherein said vacuum cleaner is a canister vacuum cleaner.
 16. The vacuum cleaner of claim 14, wherein said vacuum cleaner is an upright vacuum cleaner.
 17. The vacuum cleaner of claim 8, wherein said at least one electronic/electrical component is selected from a group consisting of (a) an agitator drive motor, (b) a printed circuit board, and (c) an agitator drive motor and a printed circuit board and wherein said at least one electronic/electrical component is cooled by said air being dawn through said suction relief inlet, over said at least one electronic/electrical component and through said passageway to said agitator cavity.
 18. The vacuum cleaner of claim 13, wherein said at least one electronic/electrical component is selected from a group consisting of (a) an agitator drive motor, (b) a printed circuit board, and (c) an agitator drive motor and a printed circuit board and wherein said at least one electronic/electrical component is cooled by said air being dawn through said suction relief inlet, over said at least one electronic/electrical component and through said passageway to said agitator cavity. 